Electric Motor Connections for Power Tools

ABSTRACT

In at least one illustrative embodiment, a power tool may comprise an electric motor comprising a rotor configured to rotate about an axis, a stator assembly including at least three windings arranged around the rotor, and at least three lugs affixed to the stator assembly, where each of the lugs is electrically coupled to one or more of the windings. The lugs may all be arranged to one side of a plane that passes through the axis. The power tool may further comprise at least three electrical wires, where each of the electrical wires is removably coupled to one of the lugs, and a control circuit configured to supply electrical power to the windings, via the electrical wires and the lugs, to drive rotation of the rotor about the axis.

CROSS REFERENCE TO RELATED APPLICATIONS

This Application is a Continuation Patent Application of U.S. patentapplication Ser. No. 14/742,527, entitled “Electric Motor Connectionsfor Power Tools,” filed on Jun. 17, 2015; this Application also claimsthe benefit of U.S. Provisional Patent Application No. 62/019,863, filedJul. 1, 2014 and entitled “Electric Motor Connections for Power Tools,”which is incorporated by reference herein in its entirety.

TECHNICAL FIELD

The present disclosure relates, generally, to power tools and, moreparticularly, to electric motor connections for power tools.

BACKGROUND

Electric motors used in power tools—by way of example, brushless directcurrent (“DC”) motors—typically require connection to three heavy gauge“phase” wires that supply the high electrical current that drives themotor. In many existing power tools, this connection is oftenaccomplished by soldering the phase wires to a printed circuit board(“PCB”) inside the motor. Traces on the PCB then conduct the highelectrical current from the phase wires to soldered termination pointswhere stator windings of the motor are coupled to the PCB. Servicing themotor in such designs may be difficult because de-soldering the phasewires from the PCB can be time consuming and risks damage to the PCB.

Other power tool designs have provided the connection between the phasewires and the stator windings of the motor via solder “lugs” that aremounted to an end of the motor. While such designs may improveserviceability, they have also increased the footprint of the motor(and, hence, the size of the power tool). First, the solder lugs in suchdesigns add length to the motor assembly. Second, because the solderlugs in such designs have typically been spaced evenly around acircumference of the motor, one or more of the phase wires must often berouted around the motor for connection to the corresponding solderlug(s).

SUMMARY

According to one aspect, a power tool may comprise an electric motorcomprising (i) a rotor configured to rotate about an axis, (ii) a statorassembly including at least three windings arranged around the rotor,and (iii) at least three lugs affixed to the stator assembly, whereineach of the lugs is electrically coupled to one or more of the windings.The lugs may all be arranged to one side of a plane that passes throughthe axis. The power tool may further comprise at least three electricalwires, wherein each of the electrical wires is removably coupled to oneof the lugs, and a control circuit configured to supply electrical powerto the windings, via the electrical wires and the lugs, to driverotation of the rotor about the axis.

In some embodiments, each of the electrical wires may be soldered to oneof the lugs. Each of the lugs may define a circular opening, and each ofthe electrical wires may be received by one of the circular openings toremovably couple each of the electrical wires to one of the lugs. Eachof the lugs may include a projection extending radially outward from thestator assembly and defining the circular opening. Each of theelectrical wires may be surrounded by one of the projections when eachof the electrical wires is received by one of the circular openings.Each projection may include an annular wall that defines the circularopening. An outer perimeter of each projection may circumscribe agenerally rectangular or circular shape.

In other embodiments, each of the lugs may include a fastener, and eachof the electrical wires may be coupled to one of the lugs by thecorresponding fastener. In still other embodiments, each of the lugs mayinclude a female receptacle, and each of the electrical wires mayinclude a male plug configured to be received in one of the femalereceptacles. The stator assembly may further include a lamination stackthat supports the windings. Each of the lugs may be affixed to anexternal surface of the lamination stack.

According to another aspect, a power tool may comprise an electric motorcomprising (i) a rotor configured to rotate about an axis, (ii) a statorassembly including at least three windings arranged around the rotor,and (iii) at least three lugs affixed to the stator assembly, whereineach of the at least three lugs is electrically coupled to one or moreof the windings. The at least three lugs may all be arranged to one sideof a plane that passes through the axis. The power tool may furthercomprise at least three electrical wires, wherein each of the electricalwires is surrounded by one of the at least three lugs to removablycouple each of the electrical wires to one of the at least three lugs.

In some embodiments, each of the electrical wires may be soldered to oneof the at least three lugs. In other embodiments, each of the at leastthree lugs may include a fastener, and each of the electrical wires maybe coupled to one of the at least three lugs by the correspondingfastener. In still other embodiments, each of the at least three lugsmay include a female receptacle, and each of the electrical wires mayinclude a male plug configured to be received in one of the femalereceptacles.

According to another aspect, an electric motor may comprise a rotorconfigured to rotate about an axis, a stator assembly including at leastthree windings arranged around the rotor, and at least three lugsaffixed to the stator assembly, each of the at least three lugs beingelectrically coupled to one or more of the windings. Each of the atleast three lugs may include a projection extending radially outwardfrom the stator assembly. The projection may define a circular openingconfigured to receive an electrical wire. The projections of the atleast three lugs may all be arranged to one side of a plane that passesthrough the axis.

In some embodiments, each projection may include an annular wall thatdefines the circular aperture. Each projection may further include apair of planar faces arranged opposite one another and interconnected bythe annular wall. An outer perimeter of each of the pair of planar facesmay circumscribe a generally rectangular shape. In other embodiments, anouter perimeter of each of the pair of planar faces may circumscribe agenerally circular shape. The stator assembly may further include alamination stack that supports the windings. Each of the at least threelugs may be affixed to an external surface of the lamination stack.

BRIEF DESCRIPTION

The concepts described in the present disclosure are illustrated by wayof example and not by way of limitation in the accompanying figures. Forsimplicity and clarity of illustration, elements illustrated in thefigures are not necessarily drawn to scale. For example, the dimensionsof some elements may be exaggerated relative to other elements forclarity.

FIG. 1 is a side elevation view of an illustrative power tool;

FIG. 2 is an end elevation view of the power tool of FIG. 1;

FIG. 3 is a magnified sectional view, taken about line 3-3 of FIG. 1, ofan electric motor included in the power tool with remaining portions ofthe power tool omitted for the sake of clarity;

FIG. 4 is a partial perspective view of various components associatedwith the electric motor of the power tool of FIG. 1 with remainingportions of the power tool omitted for the sake of clarity; and

FIG. 5 is a magnified, partial perspective view of various componentsassociated with the electric motor of the power tool of FIG. 1 withremaining portions of the power tool omitted for the sake of clarity.

DETAILED DESCRIPTION

While the concepts of the present disclosure are susceptible to variousmodifications and alternative forms, specific exemplary embodimentsthereof have been shown by way of example in the figures and will hereinbe described in detail. It should be understood, however, that there isno intent to limit the concepts of the present disclosure to theparticular forms disclosed, but on the contrary, the intention is tocover all modifications, equivalents, and alternatives falling withinthe spirit and scope of the present disclosure.

Referring now to FIG. 1, an illustrative power tool 10 is shown. Thepower tool 10 is illustratively embodied as a cordless, electric powertool (in particular, an electric, pistol-style impact tool). In variousembodiments, the power tool 10 may be embodied as a pistol-grip impacttool, an in-line impact tool, or an angle impact tool, such as aright-angle impact tool. It should be appreciated, however, that inother embodiments, the power tool may be embodied as a cordless,electric power tool that does not include an impact mechanism, such asan electric drill, drill driver, ratchet, saw, or the like.

The illustrative power tool 10 includes a tool housing 12 as shown inFIG. 1. The tool housing 12 includes a body 14 and a back cap 16. Thebody 44 defines an interior space 18 in which an electric motor 20 ofthe power tool 10 is positioned. The back cap 16 is coupled to the body14 when the power tool 10 is assembled to close off the interior space18 and define a back end 22 that is positioned opposite an output end 24of the power tool 10. The back cap 16 is coupled to the body 14 usingfasteners 26 (best seen in FIG. 2) that extend through the back cap 16and into the interior space 18.

The body 14 of the tool housing 12 defines a handle 28 on which atrigger 30 is provided as shown in FIG. 1. The trigger 30 is used toturn the electric motor 20 on/off and to control a speed of the electricmotor 20 during use of the power tool 10. A user interface 32 spacedfrom the trigger 30 is also provided on the tool housing 12,specifically on the back cap 16, as best seen in FIG. 2. In theillustrative embodiment, the user interface 32 is used to select one ofa plurality of modes of operation of the power tool 10. For instance, insome embodiments, the user interface 32 may be used to select aparticular mode of operation from among those described in U.S.Provisional Patent Application Ser. No. 62/171,504, filed Jun. 5, 2015.In other embodiments, the user interface 32 may simply regulate themaximum power supplied to the electric motor 20 when the trigger 30 isfully depressed.

Referring now to FIG. 3, the body 14 and the back cap 16 are broken awayto show components of the electric motor 20. The electric motor 20 isillustratively embodied as a brushless DC motor. As such, the motor 20generally includes a rotor 34 for providing rotational energy (e.g., toa transmission or drive train of the power tool 10) and a stator 36 forsupplying a rotating magnetic field that drives rotation of the rotor34. The motor 20 also includes a rear endbell 38 and a front endbell 40that is spaced from the endbell 38 and positioned closer to the outputend 24 of the power tool 10 than the endbell 38. The endbells 38, 40cooperate to align the rotor 34 and the stator 36 so that the rotor 34and the stator 36 extend parallel to an axis 42. The rotor 34 includes ashaft 44 supported on at least one end by a bearing 46, such that therotor 34 is configured to rotate about the axis 42. Additionally, therotor 34 includes one or more permanent magnet(s) 48 that generate amagnetic field.

Referring now to FIG. 4, the power tool 10 illustratively includes acontrol circuit 50 (shown diagrammatically), and a number of “phase”wires 52 electrically coupling the control circuit 50 to the motor 20.In the illustrative embodiment, the control circuit 50 is positioned inthe handle 28 of the power tool 10. It will be appreciated that thepower tool 10 includes one or more additional components typically foundin power tools (e.g., a transmission or drive train), which are notshown in the drawings or described herein.

Referring now to FIG. 5, the motor 20 includes a stator assembly 54 thathas a number of windings arranged around the rotor 34, with an air-gaptherebetween. In the illustrative embodiment (i.e., a four-pole,six-tooth, three-phase brushless DC motor), the stator assembly 54includes three windings that are distributed around the axis 42 to forman even number of poles. In particular, each stator winding includes apair of windings arranged on opposite sides of the axis 42. The statorwindings may be electrically connected to one another in a variety ofconfigurations, including, but not limited to, a series deltaconfiguration, a parallel delta configuration, a series wye (Y-shaped)configuration, and a parallel wye configuration.

As shown in FIG. 5, the stator assembly 54 further includes a laminationstack 56 that supports (and generally surrounds) the stator windings.The stator assembly 54 also includes a pair of insulators 58 (only oneof which is shown in FIG. 4) arranged at opposite ends of the statorassembly 54 to insulate the stator windings from other components of themotor 20.

During operation of the motor 20, when electrical power is selectivelysupplied to one of the stator windings (by the control circuit 50 viaone of the electrical wires 52), the resulting current in the statorwinding generates a magnetic field that couples to the rotor 34. Themagnetic field associated with the permanent magnet(s) in the rotor 34attempts to align itself with the magnetic field generated by the stator36, resulting in rotational movement of the rotor 34. The controlcircuit 50 may sequentially activate the stator windings so that thepermanent magnet(s) 48 of the rotor 34 continuously chase(s) theadvancing magnetic field generated by the stator windings. Theillustrative embodiment of motor 20 also includes a sensor, such as aHall Effect sensor, that provides a signal to the control circuit 50that is indicative of a current position of the rotor 34 (relative tothe stator 36). The control circuit 50 may utilize this signal whensequentially activating the stator windings to maintain proper timing ofthe commutation sequence.

In the illustrative embodiment of FIG. 5, the motor 20 further includesa number of solder lugs 60, or electrical terminals, affixed to thestator assembly 54. Each of the solder lugs 60 extends radially outwardfrom a base block 62 that is affixed to one of the insulators 58 of thestator assembly 54 as well as to an external surface 64 of thelamination stack 56 of the stator assembly 54. It is contemplated thatother mounting locations (e.g., the endbell 38) for the solder lugs 60are possible. Each of the solder lugs 60 is electrically coupled to oneor more of the stator windings. In the illustrative embodiment of FIG.5, in which the stator assembly 54 includes three windings, the motor 20also includes three solder lugs 60, with one solder lug 60 electricallycoupled to each stator winding.

The solder lugs 60 may be formed of a metal, metal alloy, or any othermaterial suitable for conducting current between the electrical wires 52and the stator windings. In some embodiments, the solder lugs 60 may bepermanently affixed to the stator assembly 54 (e.g., to the externalsurface 64 of the lamination stack 56) and/or permanently electricallycoupled to the stator windings.

As best seen in FIG. 5, each of the solder lugs 60 includes a projection66 that is coupled to and extends radially outward from the base block62. Dividers 68 are coupled to the base block 62 and extend radiallyoutward therefrom between the solder lugs 60. Specifically, one divider68A extends radially outward from the base block 62 between one pair ofthe solder lugs 60, and another divider 68B extends radially outwardfrom the base block 62 between another pair of the solder lugs 60.

The projections 66 illustratively have a generally rectangular shape asshown in FIG. 5. Specifically, an outer perimeter of each of theprojections 66 circumscribes a generally rectangular shape. In otherembodiments, however, the outer perimeter of each of the projections 66may circumscribe a shape of another suitable geometric form. Forexample, the outer perimeter of each of the projections 66 maycircumscribe a generally circular or trapezoidal shape.

Each projection 66 illustratively includes a planar face 70 and anotherplanar face 72 positioned opposite the planar face 70 as shown in FIG.5. The planar faces 70, 72 are interconnected by an annular wall 74. Theannular wall 74 of each projection 66 defines a circular aperture 76that extends through each of the planar faces 70, 72. The circularapertures 76 are sized to receive the electrical wires 52, as describedin greater detail below.

As best seen in FIG. 5, each of the electrical wires 52 is insertedthrough one of the circular apertures 76 of the projections 66 such thateach of the electrical wires 52 is surrounded by one of the projections66. In that way, the projections 66 are configured to receive andsupport the electrical wires 52 when the power tool 10 is assembled (orre-assembled). While received and supported by the projections 66, eachof the electrical wires 52 may be soldered to one of the solder lugs 60to removably couple the electrical wires 52 to the solder lugs 60.

Prior to being soldered to the solder lugs 60, ferrules 78 may be placedin contact with the electrical wires 52 as shown in FIG. 5.Specifically, ferrules 78 may be crimped onto the electrical wires 52 toprovide strain relief to the electrical wires 52 as well as prepare theelectrical wires 52 for insertion through the circular apertures 76.

In the illustrative embodiment (best seen in FIG. 4), each of the solderlugs 60 is arranged below a centerline of the motor 20 (namely, the axis42). In other words, the solder lugs 60 are all arranged to one side ofa plane that passes through the axis 42. Using FIG. 4 as an example, thesolder lugs 60 are all arranged below a plane that passes through theaxis 42 and extends generally into and out of the page of FIG. 4.Furthermore, in the illustrative embodiment, the solder lugs 60 are allarranged within a footprint of the stator assembly 54, when viewed froma perspective orthogonal to that plane. This configuration provides foreasier routing of the electrical wires 52 to the motor 20 and, thus,easier assembly of the power tool 10. This configuration also improvesserviceability of the power tool 10 by allowing easierde-soldering/re-soldering of the electrical wires 52 from/to the motor20. Furthermore, as the solder lugs 60 do not extend beyond the ends ofthe motor 20, the overall length of the power tool 10 may be reduced.

It is contemplated that, in other embodiments of the power tool 10, thesolder lugs 60 may be replaced with another type of lug 60 that allowsthe electrical wires 52 to be removably coupled to the lugs 60. Forinstance, in some embodiments, each of the lugs 60 might include afastener, such that each of the electrical wires 52 could be removablycoupled to one of the lugs 60 by tightening the corresponding fastener(and de-coupled from the lug 60 by loosening the correspondingfastener). In still other embodiments, each of the lugs 60 might includea female receptacle and each of the electrical wires 52 might include amale plug that is configured to be received in one of the femalereceptacles to removably couple the electrical wires 52 to the lugs 60.By way of example, the male plugs of the electrical wires 52 might besecured in the female receptacles of the lugs 60 via friction forces.

While certain illustrative embodiments have been described in detail inthe figure and the foregoing description, such an illustration anddescription is to be considered as exemplary and not restrictive incharacter, it being understood that only illustrative embodiments havebeen shown and described and that all changes and modifications thatcome within the spirit of the disclosure are desired to be protected.For instance, while the concepts of the present disclosure have beendescribed primarily with reference to brushless DC motors, it iscontemplated that the presently disclosed teachings may also be appliedto other types of motors, such as brushed DC motors and/or alternatingcurrent motors.

There are a plurality of advantages of the present disclosure arisingfrom the various features of the apparatus, systems, and methodsdescribed herein. It will be noted that alternative embodiments of theapparatus, systems, and methods of the present disclosure may notinclude all of the features described yet still benefit from at leastsome of the advantages of such features. Those of ordinary skill in theart may readily devise their own implementations of the apparatus,systems, and methods that incorporate one or more of the features of thepresent disclosure.

1. A power tool comprising: an electric motor comprising a rotorconfigured to rotate about an axis, a stator assembly disposed aroundthe rotor, and at least one lug affixed to the stator assembly, whereinthe at least one lug is electrically coupled to a winding on the stator;at least one electrical wire removably coupled to the at least one lug;wherein the at least one lug includes an inner peripheral wall thatdefines an opening that extends into the lug; and at least one ferrule;wherein the at least one electrical wire extends into the at least oneferrule; and wherein the at least one ferrule extends into the openingof the lug and engages the inner peripheral wall of the opening toremovably couple the at least one electrical wire to the at least onelug.
 2. The power tool of claim 1, wherein the at least one ferrule issoldered to the at least one lug.
 3. The power tool of claim 1, whereinthe at least one ferrule is removably soldered to the at least one lug.4. The power tool of claim 3, wherein the at least one ferrule is to beselectively soldered, de-soldered, and re-soldered to the at least onelug.
 5. The power tool of claim 1, wherein the at least one lug includesa projection extending radially outward from the stator assembly and theopening defining a circular opening.
 6. The power tool of claim 5,wherein the at least one electrical wire is surrounded by the projectionwhen the at least one electrical wire is received by the circularopening.
 7. The power tool of claim 5, wherein the projection includesan annular wall that defines the circular opening.
 8. The power tool ofclaim 5, wherein an outer perimeter of each projection circumscribes agenerally rectangular or circular shape.
 9. The power tool of claim 1,wherein the at least one lug includes a female receptacle and the atleast one electrical wire includes a male plug configured to be receiveda female receptacle.
 10. The power tool of claim 1, wherein the at leastone lug is at least two lugs.
 11. A power tool comprising: an electricmotor comprising a rotor configured to rotate about an axis, a statorassembly disposed around the rotor, and at least two lugs affixed to thestator assembly, wherein the at least two lugs are electrically coupledone winding on the stator; at least two electrical wires each removablycoupled to one of the at least two lugs; wherein each of the at leasttwo lugs includes an inner peripheral wall that defines an opening thatextends into each of the at least two lugs; and at least two ferrules;wherein each of the at least two electrical wires extend into one of theat least two ferrules; and wherein each of the at least two ferrulesextends into the opening of one of the lugs and engages the innerperipheral wall of the opening to removably couple each of the at leasttwo electrical wires to each one of the at least two lugs.
 12. The powertool of claim 11, wherein each of the at least two ferrules is solderedto each of the at least two lugs.
 13. The power tool of claim 11,wherein each of the at least two ferrules is removably soldered to eachof the at least two lugs.
 14. The power tool of claim 13, wherein eachof the at least two ferrules are to be selectively soldered,de-soldered, and re-soldered to each of the at least two lugs.
 15. Thepower tool of claim 11, wherein each of the at least two lugs includes aprojection extending radially outward from the stator assembly and eachof the openings defining a circular opening.
 16. The power tool of claim15, wherein each of the at least two electrical wires is surrounded bythe projection when each of the at least two electrical wires isreceived by one of the circular openings.
 17. A power tool comprising:an electric motor comprising a rotor configured to rotate about an axis,a stator assembly disposed around the rotor, and at least one lugaffixed to the stator assembly, wherein the at least one lug iselectrically coupled to a winding on the stator; and at least oneelectrical wire removably coupled to the at least one lug; wherein theat least one lug includes an inner peripheral wall that defines anopening that extends into the lug; wherein the at least one electricalwire extends into the opening of the lug and to conductively engage theinner peripheral wall of the opening to removably couple the at leastone electrical wire to the at least one lug.
 18. The power tool of claim17, wherein the at least one lug includes a projection extendingradially outward from the stator assembly and the opening defining acircular opening.
 19. The power tool of claim 18, wherein the at leastone electrical wire is surrounded by the projection when the at leastone electrical wire is received by the circular opening.
 20. The powertool of claim 17, wherein the at least one electrical wire is solderedto the at least one lug.
 21. The power tool of claim 18, wherein the atleast one electrical wire is removably soldered to the at least one lug.22. The power tool of claim 21, wherein the at least one electrical wireis to be selectively soldered, de-soldered, and re-soldered to the atleast one lug.